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Last edited 10 Apr 2018
Beam and Polystyrene Block Suspended Floor Insulation - Case Study
Project: Residential New Build Housing
Location: Wakefield, West Yorkshire
Size: 220 Plots / 8,000m2
A continuing shortage of aerated concrete blocks in the UK, caused by a reduction in the availability of fresh Pulverised Fuel Ash (PFA) is causing long delays on construction sites. PFA is a by-product of coal-fired power stations and is an essential ingredient of concrete blocks, giving them their thermal insulation properties. A warm winter, low gas prices and gradual closure of coalfired plants for cleaner energy sources has reduced the amount of PFA.
A national house builder wanted an alternative ﬂooring system for a large residential new build housing project in Wakefield, West Yorkshire which would negate the need for concrete blocks and avoid any costly on-site delays. The desired system would also need to achieve Part L Building Regulations for thermal performance and demonstrate an overall cost saving.
 Design Solution
The unique Stylite T-Beam Suspended Floor Insulation was introduced to the clients design team, who quickly saw the benefits it offered and were keen to specify the system. SPI worked closely with the client and concrete beam manufacturer to design a holistic
The Stylite T-Beam system comprises of lightweight Expanded Polystyrene (EPS) panels contour cut to suit the profile of the concrete beams. The interlocking EPS panels are installed between the beams with the “toe” extending underneath to provide the all round insulation and eliminating cold bridging.
The panels specified were 230mm deep to achieve a U-value of 0.22 W/m2K meeting the clients requirements for Building Regulations. To complete the ﬂoor design a macro fibre concrete screed topping of 75mm was specified.
 Key Benefits
- Quick and reliable deliveries
- Excellent thermal performance
- Interlocking panels prevent cold bridging
- Fast installation reduces labour costs
- Lightweight blocks reduce health and safety concerns
After receiving on-site training from SPI the ground work contractor was “Very impressed
by the speed of installation” and could see how easy the system was to install. “We can
now complete around two houses in the same time it would have taken to do one with traditional concrete blocks and the polystyrene is so light it massively reduces our manual handling”. Project Site Manager
 Related articles on Designing Buildings Wiki
- Beam and Infill Suspended Floors.
- Cavity wall insulation
- Celotex RS5000 PIR insulation.
- Conventions for U-value calculations (2006 edition) BR 443.
- Designing out unintended consequences when applying solid wall insulation FB 79.
- EPS Geofill Civil Engineering - Case Study.
- Insulation for ground floors.
- Passivehaus Foundation Insulation - Case Study.
- Polyurethane spray foam in structurally insulated panels and composite structures.
- Profiled and cut to fall roof insulation - case study.
- Solid wall insulation.
- Sound insulation.
- Transparent insulation.
--Styrene Packaging and Insulation Ltd 12:52, 10 Apr 2018 (BST)
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